This disclosure relates generally to building construction and more particularly to systems and methods for constructing buildings using a frame structure that facilitates installation of wall panels to form the building enclosure.
This disclosure is directed to systems and methods that are used in the construction of residential, commercial or other types of buildings. One embodiment of the invention comprises a system in which a prefabricated construction panels are attached to a frame assembly to form a building. In this embodiment, a metal frame is constructed from prefabricated components, such as wall base tracks, “I” stud assemblies, and top beam assemblies. Building panels are then attached to the frame to form walls and complete the building enclosure.
One embodiment comprises a component for a use in a building system. The frame member is a substantially rigid, elongated member such as a stud. The frame member has an attachment portion extending outward so that construction panels can be secured to it. In a particular embodiment, the stud is designed to be used in a frame system to support vertical wall panels. The stud consists of a pair of metal C-channel studs that are oriented back-to-back with a stiffener plate between them. The stiffener plate extends outward from the stud so that it can be used to secure the wall panels against the stud. More specifically, the stiffener plate has slots through it that allow biscuits to be placed through the stiffener plate and into the edges of the wall panels that abut the stiffener plate. The biscuits hold the edges of the wall panels in alignment with each other and, because the biscuits extend through the slots in the stiffener plate, the wall panels are held against the stud, thereby stiffening the wall formed by the panels.
An alternative embodiment comprises a building system that incorporates frame members having an attachment portion such as that described above. The building system includes a frame consisting of a base track, a top beam, and one or more studs. The studs are vertically oriented with their lower ends connected to the base track and their upper ends connected to the top beam. The building system also includes a set of construction panels that are secured to the frame. Each construction panel has slots in its edges to accept biscuits which maintain alignment of the panel edges. The attachment portion of each stud has slots through which the biscuits are inserted so that the construction panels are held against the studs. Channels may be provided in the base track and/or top beam to receive the construction panels. The channel in the base track may include supports configured to elevate the construction panels above the bottom of the base track. The top beam may include tabs for attachment of trusses or other support members to the top beam.
Numerous other alternative embodiments are also possible.
Other objects and advantages of the invention may become apparent upon reading the following detailed description and upon reference to the accompanying drawings.
While the subject matter of the present disclosure is subject to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and the accompanying detailed description. It should be understood, however, that the drawings and detailed description are not intended to limit the subject matter to the particular embodiment which is described. This disclosure is instead intended to cover many modifications, equivalents and alternatives.
One or more embodiments of the system are described below. It should be noted that these and any other embodiments described below are exemplary and are intended to be illustrative rather than limiting.
The present disclosure describes various systems and methods that are used in the construction of buildings. The buildings may be residential, commercial or other types of buildings.
The features described herein are part of an overall system in which a prefabricated construction panels are assembled to form a wall. In one embodiment, a frame is first constructed, and then the building panels are assembled to complete the building enclosure. The features described in this disclosure relate to the mechanisms employed in the frame to facilitate assembly of the panels or provide improvements in the resulting structure.
Referring to
Referring to
Wall base track 110 is normally fastened to the foundation of the building or, in the case of multi-floor construction, to the structure of the floor below. “I” studs 120 are positioned in a space in the center of wall base track 110 and are fastened to the track. Top beam assembly 130 is then positioned on top of the “I” studs and is fastened to the “I” studs to complete the frame. After the frame is assembled, wall panels 140 can be attached to the frame to form the walls of the building as shown in
Referring to
In the embodiment of
It can be seen in
Keeping the panel above the bottom of the track serves several purposes. For instance, elevating the panel above the bottom of the track eliminates the need to provide waterproofing where the panel would otherwise come into contact with the foundation. This waterproofing would be necessary to prevent water damage to the panels if they were simply sitting on the bottom of the track. Additionally, by elevating the panel, a gap is provided between the panel and the bottom of the track so that the track can be bolted to the foundation on which it is installed. Since it is preferable to secure the track at its outer edge, providing the gap between the panel and the bottom of the track allows the bolt and the corresponding nut to be positioned in the gap under the panel and to thereby secure the edge of the track.
It can also be seen in
Referring to
It can be seen from the front and top views in
Stiffener plate 320 is used between C-channel studs 310 and 311 to provide additional stiffness to the assembled wall panels. The additional stiffness is provided by configuring stiffener plate 320 so that a portion 321 of the plate extends forward from between C-channel studs 310 and 311, as can be seen in the side view of the “I” stud. Portion 321 of the stiffener plate extends forward by an amount that is just less than the thickness of the wall panels with which it is used. It can also be seen in the figure that portion 321 of the stiffener plate does not extend the full length of the “I” stud, as the ends of the “I” stud must fit between the tracks of wall base track assembly 110 and within the top track of top beam 130.
This portion of stiffener plate 320 that extends outward from the C-channel studs has several slots 322 that are sized to accommodate disks or “biscuits.” Each of wall panels 140 has slots in its sides to accommodate these biscuits. The biscuits are used to maintain alignment of adjoining ones of the wall panels in essentially the same way wood biscuits are used in the joining of boards to form larger wooden panels. In the case of wall panels 140, the biscuits extend from a slot in the edge of one panel, through one of the slots 322 in the stiffener plate, and into a slot in the edge of an adjacent panel.
The manner in which the wall panels, stiffener plate and biscuit fit together is shown in
Referring to
Referring to the end view, in can be seen that the body 510 of the beam consists of sheet metal that is formed into a deep U-channel. a set of indentations 540 are made in the sides of beam body 510 in order to strengthen the beam. A top plate 520 is spot welded to the top of the beam (the open end of the U-channel.) A wall top track 530 is spot welded to the bottom of the beam.
Wall top track 530 is configured to fit over the tops of the “I” studs, as well as the tops of the installed wall panels. Top plate 520 includes several tabs 550 that extend upward from the beam. Tabs 550 may be formed, for example, by cutting three sides of each tab from the top plate and then bending the tabs upward, leaving corresponding holes in top plate 520. Tabs 550 are used to attach support members such as trusses to the top of the beam. These trusses may be roof trusses if the frame is for the uppermost floor of the building (or a single-story building,) or they may be floor trusses if additional floors will be built above the frame structure.
The components of the building system described above can be installed in various ways. Typically, at least a portion of the frame (wall base track, “I” studs and top beam) are assembled, and then the wall panels are installed in/on the frame. In one embodiment, the base track is installed, and then the “I” studs and wall panels are installed sequentially. In other words, a first “I” stud is installed, and an adjoining wall panel is installed with one or more biscuits extending from a groove in the edge of the panel through corresponding slots in the stiffener plate of the “I” stud. Then, Another “I” stud is installed at the opposite edge of the installed wall panel. Biscuits are placed through the slots in the stiffener plate of the second “I” stud and into grooves in the edge of the installed wall panel. Then a second wall panel is installed so that the biscuits are positioned in grooves in the edge of the panel. This process is repeated for additional wall panels and “I” studs.
Because it may be necessary in the sequential installation of alternating “I” studs and wall panels to plumb each additional panel, it may be more efficient to install a more complete frame before installing the wall panels. In one embodiment, a portion of the frame for an entire wall may be assembled and then raised and made plumb. Partial frames for the adjoining walls may be assembled and joined together to form the frame for a room, or even an entire building. Having ensured that these wall frames are square and plumb, no additional labor is necessary for this purpose. The panels can simply be installed in/on the frame, knowing that the walls will be square and plumb.
In this second method of assembly, the initial wall frame may include only a portion of the studs that will ultimately be needed. After the initial frame is up, additional studs (e.g., “I” studs) can be installed, along with the adjoining wall panels, as described above. Alternatively, the initial frame may include incomplete studs (i.e., studs that do not yet have a stiffener plate.) In this case, the stiffener plate for a stud may be attached to the stud after the wall is erected, and the wall panels can be attached to the studs, stiffener plates and each other essentially as described above. There may, of course, be other ways in which the components of the present building system may be installed.
As noted above, the foregoing disclosure describes only exemplary embodiments of the systems and corresponding methods. There may be many alternative embodiments that are within the scope of this disclosure, such as the use of a base wall track that includes only a single U/J-channel track or has a different configuration than shown above, the use of a top beam that has no tabs or no strengthening indentations or has other configurations than shown above, the use of a stud that has only a single C-channel stud with the stiffener plate or has a different configuration, or other similar variations on the above system.
This application claims the benefit of U.S. Provisional Patent Application 60/730,604, entitled “Systems And Methods For Building Construction” by Robert Olvera and George Stevenson, filed Oct. 27, 2005, which is incorporated by reference as if set forth herein in its entirety.
Number | Date | Country | |
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60730604 | Oct 2005 | US |